Aboveground waterproofing boards, systems, and methods

ABSTRACT

Systems, methods, and boards for insulating building foundations are provided. The boards can be fiberglass, and the boards may have a pre-applied scrim. At least one coating can be provided on at least one face of the insulation boards. The boards can be applied to a portion of the building foundation above the grade line.

RELATED APPLICATIONS

This application claims priority to and any other benefit of U.S.Provisional Patent Application No. 60/591,216 filed Jul. 26, 2004, whichis expressly incorporated by reference herein.

BACKGROUND

Waterproofing and insulation of building foundations can be one goal fornew or existing construction, and existing systems can providewaterproofing and/or insulation to building foundations. However, suchsystems can be difficult to install, and such systems may not provideadequate protection to an above grade portion of the foundation. Thus,there remains a need in the art for systems and methods of providinginsulation and/or waterproofing to building foundations.

SUMMARY

In accordance with embodiments of the present invention boards areprovided. The boards can comprise an insulation board substrate having afirst surface and a second surface; and a planar scrim having an openstructure secured to at least a portion of the insulation boardsubstrate. The scrim is secured to the insulation board by placing thescrim in contact with a fiberglass woolpack and curing the woolpack suchthat the insulation board substrate with the scrim secured to the firstsurface is formed.

In accordance with further embodiments of the present invention, methodsfor producing boards are provided. The methods comprise providing aplanar scrim having an open structure such that it is disposed on atleast a portion of a first surface of a fiberglass woolpack andsubsequently curing the fiberglass woolpack such that an insulationboard substrate having the scrim secured to at least a portion of afirst surface of said insulation board substrate is formed.

In accordance with embodiments of the present invention, systems forinsulation of building foundations are provided. The systems comprise atleast one insulation board comprising an insulation board substratehaving a pre-applied scrim on at least a portion of a first face of theat least one insulation board substrate and a coating. The at least oneinsulation board is disposed for installing on a building foundationsuch that the at least one insulation board covers at least a portion ofthe building foundation above a grade line. The coating is disposed forapplying to the first face of the insulation board substrate such thatthe coating provides waterproofing properties to the system.

In accordance with embodiments of the present invention, methods forproviding aboveground insulation are provided. The methods compriseapplying insulating boards to cover at least a portion of theaboveground portion of a building foundation and coating the insulatingboards with an elastomeric coating after the insulating boards have beenapplied to the foundation.

In accordance with other embodiments of the present invention, methodsfor providing aboveground insulation are provided. The methods compriseapplying a plurality of insulating boards each having a first face, asecond face, a top edge, a bottom edge, and a pre-applied scrim on saidfirst face to a building foundation such that the second face of each ofthe plurality of insulating boards is proximate to the buildingfoundation and such that the plurality of insulating boards covers thefoundation from at least proximate to a grade line of the foundation toproximate a sill plate of said building foundation. The methods furthercomprise fastening the insulating board proximate to the bottom edge tothe foundation with a plurality of fasteners and applying mesh tape tothe top edge of the insulating boards such that at least a portion ofthe mesh tape at the top edge of the boards contact one of the sillplate and a band board installed to the sill plate. The methods furthercomprise fastening the mesh tape to the sill plate or the band boardwith a plurality of fasteners and applying a coating over the insulatingboards and the mesh tape.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

The following detailed description of embodiments of the presentinvention can be best understood when read in conjunction with thefollowing drawings, where like structure is indicated with likereference numerals and in which:

FIG. 1 is an illustration of a board in accordance with embodiments ofthe present invention; and

FIG. 2 is an illustration of a system in accordance with embodiments ofthe present invention.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

The present invention will now be described with occasional reference tospecific exemplary embodiments of the invention. This invention may,however, be embodied in different forms and should not be construed aslimited to the embodiments set forth herein. Rather, these embodimentsare provided so that this disclosure will be thorough and complete.

Unless otherwise defined, all technical and scientific terms used hereinhave the same meaning as commonly understood by one of ordinary skill inthe art to which this invention belongs. The terminology used in thedescription of the invention herein is for describing particularembodiments only and is not intended to be limiting of the invention. Asused in the description of the invention and the appended claims, thesingular forms “a,” “an,” and “the” are intended to include the pluralforms as well, unless the context clearly indicates otherwise. Allpublications, patent applications, patents, and other referencesmentioned herein are incorporated by reference in their entirety.

The present invention provides boards that may be used in abovegroundinsulation or covering of foundations. The present invention providessystems and methods of insulating, finishing, or covering at least theaboveground portion of a foundation. The present invention provides kitsfor insulating, finishing, or covering at least the above ground portionof a foundation.

In accordance with embodiments of the present invention, insulationboards are provided and methods of making insulation boards areprovided. The insulation boards comprise an insulation board substratehaving a scrim that is applied to the insulation board substrate duringthe manufacture of the board. For purposes of defining and describingthe present invention, the term “scrim” shall be understood as includingany suitable planar woven, non-woven, polymeric, glass or other suitablescrim structure that may be applied to a board in order to enhanceapplication of coatings to the board and/or provide reinforcement to acoating applied to the board. For example, as shown in FIG. 1, aninsulation board 10 may comprise an insulation board substrate 12 havinga first surface 14 and a second surface 16. The first surface 14 canhave a scrim 18 applied to the first surface 14 during the manufactureof the insulation board 10. It will be understood that the scrim 18 canbe applied to only a portion of the first surface 14. For example, thescrim 18 can be applied such that the edges of the scrim are proximateto the edges of the board 10. Alternatively, the scrim 18 can be appliedsuch that the edges of the scrim are contiguous with the edges of theinsulation board substrate 12.

The insulation board substrate 12 may be any suitable type of fiberglassinsulation board. For example, the insulation board substrate may be adense fiberglass board similar to the Owens Corning WARM-N-DRI®Foundation Board. The insulation board substrate 12 may have anysuitable dimensions or thickness. The scrim 18 can be any suitable scrimthat has an open structure that is open enough to allow coating to flowthrough the scrim 18. In one example, the open structure is an openweave or open mesh structure. In another example the open structure is anon-woven structure having interstices between at least some of theadjacent material fibers or threads. In one example, the scrim 18 can bemade of a material having between about 30×30 to about 3×3 threads perinch. In another example, the scrim 18 can be made of a material havingabout 10×10 threads per inch. In another example, the scrim 18 can be aglass scrim having G37, G75, or G150 yarns and a temperature resistantbinder.

The scrim 18 can be secured to the insulation board substrate 12 in anysuitable manner. In one example, the insulation board substrate 12 canbe a fiberglass board, and the scrim 18 can be placed in contact with atleast a portion of the top of the woolpack prior to curing the woolpackin a fiberglass drying and curing oven. It will be understood that anysuitable manufacturing system can be used to produce the board 10 havingthe scrim 18. In one example, the woolpack having the scrim 18 incontact therewith can be compressed during the curing to form a denseboard 10. In another example, the woolpack can be cured at a temperaturebetween about 400° F. to about 600° F. or about 450° F. to about 500° F.The scrim 18 is secured to the board 10 during curing in the fiberglassdrying oven. No other adhesives are necessary to secure the scrim 18 tothe board 10. The pre-applied scrim 18 allows the board 10 to be easilyinstalled on a structure and to have a coating immediately applied tothe board 10. Thus, the additional step of installing a scrim overinstalled board is not required.

In accordance with other embodiments of the present invention, systems,kits, and methods for providing above ground insulation to foundationsare provided. Referring to FIG. 2, a system 21 installed on a foundation20 is illustrated. The exemplary foundation 20 has a wall portion 22, asill plate 24, and a band board 26. It will be understood that anysuitable foundation structure may be insulated in accordance with thepresent invention. The foundation has a portion 28 below the grade line30 and a portion 32 above the grade line 30.

During the construction of a structure, both the below grade portion 28and the above grade portion 32 can be exposed. In order to waterproofand insulate the above grade portion 32, a waterproof membrane 34 isapplied to the wall portion 22 of the foundation 20 to within about 2inches of the sill plate 24 or any openings 36. Alternatively, thewaterproof membrane 34 can be applied to stop proximate to the gradeline if it is desirable to maintain water permeability of theabove-grade portion of the foundation 20. The waterproof membrane 34 canbe any suitable membrane. For example, the waterproof membrane 34 can bean elastomeric spray-on polymer modified asphalt membrane such as aTUFF-N-DRI® membrane available from Tremco Barrier Solutions. The belowgrade portion 28 of the foundation 20 may be further insulated with aninsulation board such as a WARM-N-DRI® Foundation Board (not shown). Ifthe below grade portion 28 of the foundation 20 is insulated with aninsulation board, the board will terminate below the grade line 30.

Insulation boards 10 having a pre-applied scrim 18 are prepared forinstallation by beveling the top edge 38 of the board at an angle ofabout 10° to about 60°. For example, the boards 10 are beveled at a 45°angle as shown. The beveled edge 38 provides a continuous water drainageplane once the board 10 is coated as discussed herein. The boards 10 areinstalled to cover the above grade portion 32 of the foundation. Theboards 10 are also disposed around openings such as a window opening 36in the foundation 20. The edges of the boards 10 around openings 36 canbe beveled as appropriate to provide a better appearance or enhancewater drainage once the boards 10 are coated as discussed herein.Alternatively, the edges of the board 10 may not be beveled aroundopenings 36.

Additionally, the boards 10 can be installed to cover a portion of thesill plate 24 or the band board 26. In one example, the boards 10 can beinstalled to within about 1 inch above or about 1 inch below the sillplate 24. The boards 10 may also be installed to be below the grade line30. In one example, the boards 10 can be installed to be at least aboutsix inches below the grade line 30. The boards 10 may extend below thegrade line 30 any suitable distance up to the frost line if desired. Theboards 10 may have any suitable dimensions. For example, the boards 10may be 4×8 foot boards. The boards 10 can be 1 3/16 inches thick, 2⅜inches thick, or be of any other suitable thickness. In someapplications, more than one run of boards 10 will be required-to providesuitable coverage to the above grade portion 32 of the foundation 20when the distance from the sill plate 24 to 6 inches below the gradeline 30 exceeds the maximum height of the boards 10.

As an aid to installation, the boards 10 may be temporarily fixed to thefoundation 20 during installation by using clips 40. In addition, one ormore clips 40 can be installed on the sill plate 24 or the band board 26prior to the installation of the boards 10 at any suitable interval. Theclips 40 can be angled with an angle that matches the beveled edge 38angle of the boards 10 and set to meet the board 10 at the proper topedge height, and the top 38 of the board 10 can be seated against thejunction between the foundation 20 and the clip 40 to aid ininstallation. It will be understood that the clips 40 can be of anysuitable dimension. For example, the clips 40 can be sized such that alarge number of clips 40 are provided along a given foundation wall 22.Alternatively, the clips 40 can be sized to span an entire section ofthe foundation wall 22. The board 10 is fastened near the bottom 42 ofthe board 10 with a suitable number of mechanical fasteners 44. Forexample, one fastener 44 can be installed every two feet. When only onerun of boards 10 is necessary, the fasteners 44 can be hidden below thegrade line 30. If more than one run of boards 10 is necessary, thefasteners 44 above the grade line 30 can be spackled prior to coating asdescribed hereinafter. Any suitable type of fasteners such as pneumaticor hand driven fasteners may be used.

Seams 46 between the boards 10 can be taped with a mesh tape 48.Additionally, openings 36 in the foundation can be taped with a meshtape 48. Corner protectors can be applied. The top beveled edge 38 ofthe board 10 is also taped with a run of mesh tape 50 along the bevelededge 38 and onto the sill plate 24 or the band board 26. The mesh tape50 on the sill plate 24 and/or the band board 26 is fastened withfasteners 52 to the sill plate 24 or the band board 26. This attachmentof the mesh tape 50 to the sill plate 24 or the band board 26 obviatesthe need fasteners to fasten the top of the board 10 to the foundation20 when coated as discussed herein.

Once the boards 10 have been installed, a coating (not shown) can beapplied to cover the boards 10 and mesh tape 48, 50. It will beunderstood that the present invention is also directed to boards havinga coating in accordance with the present invention whether or not thecoating is applied in place as described herein. The coating can providewaterproofing properties to the insulation system. The coating can havea dry thickness of between about 10 to about 60 mils. For example, thecoating may have a thickness of about 40 mils dry. This high thicknesscoating allows the surface to have a dimensional texture if desired.Additionally, the coating can provide a board 10 surface having enhanceddamage resistance.

The coating may be any suitable high quality elastomeric coating. Forexample, the coating could be an acrylic, styrene-acrylic,vinyl-acrylic, vinyl, or other suitable polymer type coating. Forexample, Horizon™ coatings from Tremco Barrier Solutions may be used. Inanother example, the coating can be an elastomeric coating havingcellulosic fibers as filler. For example, the coating can comprise about25% to about 55% resin having 50% solids, about 25% to about 75% fillersand pigments, about 0% to about 40% water, and about 0% to about 6%additives. In another example, the coating can comprise 40% resin, 52%fillers and pigments, 5% water, and 3% additives. The resin can comprisean acrylic, styrene-acrylic, vinyl-acrylic, vinyl, or other suitableresin. The filler can comprise a particulate and/or fibrous filler, suchas calcium carbonate, fly ash, and cellulose or other polymeric fibersor microspheres.

The coating can be a matte finish coating or an aggregate finishcoating. For purposes of defining and describing the present invention,the term “matte finish coating” shall be understood as referring to acoating that does not contain a substantial amount of coarse aggregatematerial. For purposes of defining and describing the present invention,the term “aggregate finish coating” shall be understood as referring toa coating that contains coarse aggregate. For purposes of defining anddescribing the present invention, the term “coarse aggregate” shall beunderstood as referring to an aggregate that can produce a surfacefeature in the finish of the coating. Any suitable type of coarseaggregate may be used. For example, calcium carbonate aggregate may beused in the coating. In another example, an aggregate that has 0%passing through a 16 mesh sieve, 2% passing through an 18 mesh sieve,64% passing through a 30 mesh sieve, 33% passing through a 40 meshsieve, and 2% passing through a greater than 40 mesh sieve can be used.

When an elastomeric coating containing cellulosic fibers is used inconjunction with a fiberglass board 10, the coated surface displays asurprising degree of damage resistance to abrasion and puncture impactsand other types of damage. Without wishing to bound to any particulartheory, it is believed that the fibers in the fiberglass board 10reinforce the coating. It is also believed that the coating fibers mayinteract synergistically with the fiberglass fibers of the board 10 toproduce a more damage-resistant coated board. This enhanced damageresistance is desirable because the boards 10 and coating may experienceimpacts from people, yard equipment, etc., during the life of thebuilding.

The coating can be applied in any suitable manner. In one example, thecoating is applied by spraying coating, such as a matte and/or aggregatecoating, onto the insulation boards 10 and the mesh tape 48, 50. Inanother example, a two-step wet on wet process may be used. In the firststep, a high-output airless sprayer may be used to apply a mattecoating. In the second step, an air-atomized sprayer may be used toapply an aggregate coating on top of the wet matte coating. Thistwo-step application procedure provides a fast wet-on-wet application ofthe coating. Additionally, the use of an aggregate coating providesincreased damage resistance and aesthetic improvement to the insulationsystem 21. In one example, about 75% of the dry thickness of the coatingmay be a matte coating and about 25% of the dry thickness of the coatingmay be an aggregate coating. In another example, the ratio of the mattecoating to the aggregate coating may be between about 1:4 to 4:1.

The coated boards 10 provide aboveground insulation. Additionally, thecoated boards 10 provide a continuous water shedding plane on thefoundation of a building. The coated boards 10 can also serve as a sillsealer because the seam between the sill plate 24 and the foundation 20and/or the seam between the sill plate 24 and the band board 26 can becovered by mesh 50 and a coating. The insulation system 21 does notrequire the use of cementicious products. The coated boards 10 stopwater from reaching the foundation 20, but the coated boards 10 arevapor permeable. Therefore, the insulation system 21 offers vaporpermeable insulation of the foundation of buildings. It will beunderstood that the boards 10 and coatings of the present invention canbe configured and installed to cover any building foundation.

It will be readily apparent to those skilled in the art that variouschanges may be made without departing from the scope of the invention,which is not to be considered limited to what is described in thespecification.

1. A system for insulation of building foundations, comprising: at leastone insulation board comprising an insulation board substrate having apre-applied scrim on at least a portion of a first face of said at leastone insulation board substrate; and a coating, wherein: said at leastone insulation board is disposed for installing on a building foundationsuch that said at least one insulation board covers at least a portionof the building foundation above a grade line; and said coating isdisposed for applying to said first face of said insulation boardsubstrate such that said coating provides waterproofing properties tosaid system.
 2. The system as claimed in claim 1 further comprising saidat least one insulation board disposed for installing on said buildingfoundation such that a top edge of said at least one insulation board isproximate to the sill plate of said building foundation
 3. The system asclaimed in claim 1 further comprising at least one clip, wherein said atleast one clip is disposed to be installed on the sill plate of thefoundation in order to hold said at least one insulation board in place.4. The system as claimed in claim 1 wherein said system comprises aplurality of said insulation boards, and said system further comprisingmesh tape that is disposed for placement over a joint between adjacentinsulation boards on the foundation.
 5. The system as claimed in claim 4wherein said mesh tape is further disposed for placement over a top edgeof said plurality of insulation boards and proximate to said sill plate.6. The system as claimed in claim 1 wherein said coating comprises anelastomeric coating.
 7. The system as claimed in claim 6 wherein saidelastomeric coating is selected from acrylic, styrene-acrylic,vinyl-acrylic, and vinyl type coatings.
 8. The system as claimed inclaim 6 wherein said elastomeric coating is selected from one of a mattefinish coating and an aggregate finish coating.
 9. The system as claimedin claim 6 wherein said elastomeric coating comprises Horizon™ coating.10. The system as claimed in claim 6 wherein said elastomeric coatingcontains cellulosic fibers.
 11. The system as claimed in claim 1 whereinsaid at least one insulation board has a bottom edge, and wherein saidbottom edge is disposed for installing at least six inches below saidgrade line.
 12. The system as claimed in claim 1 wherein said top edgecomprises a beveled edge.
 13. The system as claimed in claim 12 whereinsaid beveled edge comprises a bevel angle of between about 10° to about60°.
 14. The system as claimed in claim 1 further comprising awaterproof membrane for installing between said foundation and said atleast one insulation board.
 15. The system as claimed in claim 1 saidsystem further comprising fasteners to attach said at least oneinsulation board to said foundation.
 16. The system as claimed in claim1 wherein said at least one insulation board and said coating are vaporpermeable.
 17. A method for providing aboveground insulation,comprising: applying insulating boards to cover at least a portion ofthe aboveground portion of a building foundation; and coating saidinsulating boards with an elastomeric coating after said insulatingboards have been applied to said foundation.
 18. A method for providingaboveground insulation, comprising: applying a plurality of insulatingboards each having a first face, a second face, a top edge, a bottomedge, and a pre-applied scrim on said first face to a buildingfoundation such that said second face of each of said plurality ofinsulating boards is proximate to said building foundation, and suchthat said plurality of insulating boards covers said foundation from atleast proximate to a grade line of said foundation to proximate a sillplate of said building foundation; fastening said insulating boardproximate to said bottom edge to said foundation with a plurality offasteners; applying mesh tape to said top edge of said insulating boardssuch that at least a portion of said mesh tape at said top edge of saidboards contact one of said sill plate and a band board installed to saidsill plate; fastening said mesh tape to said sill plate or said bandboard with a plurality of fasteners; and applying a coating over saidinsulating boards and said mesh tape.
 19. The method as claimed in claim18 applying mesh tape to joints between adjacent insulating boards. 20.The method as claimed in claim 18 further comprising applying awaterproof membrane to at least a portion of said foundation prior tosaid step of applying a plurality of insulating boards.
 21. The methodas claimed in claim 20 wherein said waterproof membrane is appliedbetween said foundation and said insulating board.
 22. The method asclaimed in claim 20 wherein said waterproof membrane is applied byspraying said membrane on said foundation.
 23. The method as claimed inclaim 18 wherein said step of applying said coating to said insulatingboards comprises applying said coating such that said coating has athickness of between about 10 mils to about 60 mils when said coating isdry.
 24. The method as claimed in claim 18 wherein said step of applyingsaid coating to said insulating boards comprises applying said coatingover said mesh tape at said top edge of said insulating boards such thata continuous water shedding plane on said foundation is formed.
 25. Themethod as claimed in claim 18 wherein said step of applying said coatingto said insulating board comprises applying a matte coating to saidinsulating boards and said mesh tape and subsequently applying anaggregate coating on said matte coating while said matte coating is wet.26. The method as claimed in claim 18 wherein said step of fasteningsaid insulating board comprises fastening said insulating boards to saidfoundation with a plurality of mechanical fasteners below said gradeline.
 27. The method as claimed in claim 18 further comprising bevelingsaid top edge of said insulating boards before said step of applyingsaid boards.
 28. The method as claimed in claim 27 wherein said step ofbeveling said top edges of said insulating boards comprises bevelingsaid top edge at an angle of between about 10° to about 60°.
 29. Themethod as claimed in claim 18 further comprising providing insulation tosaid portion of said foundation below said grade line of saidfoundation.